Integrated data acquisition system for product in transit

ABSTRACT

A data acquisition system includes a product for shipment to an end user, a sensor system removably connected to the product for recording environmental conditions to which the product is exposed, and a computing device, which upon being connected to the product, is operable to retrieve the recorded environmental conditions. The product may be operable to control the operation of the sensor system, or the sensor system may be operable to record environmental conditions independent of the operation of the product.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates to a data acquisition system forarticles in transit. More particularly, the present invention relates toa system for recording environmental conditions to which a product issubjected during transport.

[0003] 2. Brief Description of Related Developments

[0004] Consumer and industrial products are frequently distributed toend users throughout the world. A particular distribution network mayinclude air travel, water travel, and land travel. The various modes oftravel may utilize airplanes, cargo ships, trucks, and rail transport.While in the distribution network, products may be subject to a numberof environmental conditions including for example, vibration, shock,temperature, humidity, barometric pressure, etc. While the products maybe conveyed by various types of transport, and subjected to variousenvironmental conditions, it is important that they arrive at an enduser's location in good condition.

[0005] One method of ensuring delivery in good condition is to packagethe products appropriately. In some enterprises, a department or someother functional entity may be dedicated to making certain that productpackaging functions effectively. In order to do so successfully,information regarding the range of environmental conditions that aproduct may experience is required. One way to gather this informationis to include a general purpose data gathering instrument, also referredto as a data recorder, data saver, or data logger, in the package with aproduct. The instrument typically gathers environmental data duringtransport. Upon arrival at a destination, the data may be retrieved andanalyzed. Once acquired, the data may be used to enhance not only thepackaging design but also the design of the product itself may beimproved if desired.

[0006] General purpose recording instruments are disadvantageous in thatthey are usually expensive and as a result may only be used on a samplebasis. They may also be bulky, making integration into a particularpackaging design difficult, and in some instances requiring modificationof the packaging. If an enterprise uses multiple packaging designs, theintegration or modification may have to be done for each type of design.In addition, extracting data from the instrument may require specialinterfaces and software.

[0007] It would be advantageous to provide a data acquisition systemthat is inexpensive and easily integrated into an existing product sothat it may be used to track a large sample population, or ideally eachindividual product as it travels through the distribution network to theend user. It would also be advantageous to provide a data acquisitionsystem that may be used without modifying existing packaging. It wouldbe additionally advantageous to provide a data acquisition system fromwhich data may be easily retrieved in a usable format.

SUMMARY OF THE INVENTION

[0008] The present invention provides for a data acquisition system thataddresses the above-identified limitations.

[0009] In one embodiment, the present invention is directed to a dataacquisition system, including a product for shipment to an end user, asensor system removably connected to the product for recordingenvironmental conditions to which the product is exposed, and acomputing device, which upon being connected to the product, is operableto retrieve the recorded environmental conditions.

[0010] In another embodiment, the present invention is directed to aproduct for shipment to an and user, including a sensor system removablyconnected to the product for recording environmental conditions to whichthe product is exposed, and a communication port for communicating witha computing device, which upon being connected to the product, isoperable to retrieve the recorded environmental conditions.

[0011] In still another embodiment, the present invention is directed toa sensor system for removable connection to a product for shipment to anend user, the sensor system including an interface to the product, andone or more sensors for recording environmental conditions to which theproduct is subjected. The sensor system is operable to provide therecorded environmental conditions to a computing device, upon thecomputing device being connected to the product.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The foregoing aspects and other features of the present inventionare explained in the following description, taken in connection with theaccompanying drawings, wherein:

[0013]FIG. 1 shows a schematic diagram of a data acquisition system inaccordance with the teachings of the present invention; and

[0014]FIG. 2 is a block diagram of a sensor system integrated as part ofthe data acquisition system.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] Referring to FIG. 1, a data acquisition system 100 incorporatingfeatures of the present invention is illustrated. Although the presentinvention will be described with reference to the embodiment shown inthe drawings, it should be understood that the present invention can beembodied in many alternate forms of embodiments. In addition, anysuitable size, shape or type of elements or materials could be used.

[0016] Data acquisition system 100 generally includes a data recordingfunction performed by components within a product 105, and a dataretrieval and analysis function represented by an enterprise 140communicating with product 105 through a network 145.

[0017] The present invention provides a data acquisition system that iseasily and inexpensively integrated into an existing product, allowingit to be used to track a large sample population, or each individualproduct as they pass through a distribution channel. The presentinvention may be implemented without altering existing packaging forproduct 105 and also provides for data retrieval in an advantageousmanner.

[0018] In the embodiment shown in FIG. 1, product 105 is generally onethat is conveyed through a distribution channel. Product 105 generallyincludes a microcontroller 110, typically having a microprocessor 115,on-board memory 120, an analog to digital converter (A/D) 125, a realtime clock interrupt controller (RTC) 130, and a universal asynchronousreceiver transmitter (UART) 135. Microcontroller 110 may be connected toa communications network 145, that may include any network suitable forcommunication, for example, the Internet, the Public Switched TelephoneNetwork (PSTN), a wireless network, a wired network, a virtual privatenetwork (VPN) etc. Communication may be executed using any suitableprotocol, including X.25, ATM, TCP/IP, etc.

[0019] Microcontroller 110 may be connected to an enterprise 140 throughnetwork 145. Enterprise 140 could be an office of a manufacturer ofproduct 105 or a provider of goods and services related to product 105.Enterprise 140 preferably includes a computer 150 for communicating withmicrocontroller 110. Enterprise 140 may also include other computers 155connected to computer 150 through an internal network 160.

[0020] Product 105 also includes an integrated sensor system 165 inaccordance with the teachings of the present invention, connected tomicrocontroller 110. In one embodiment, on-board memory 120 onmicrocontroller 110 may include programs 170 for controlling andinteracting with sensor system 165.

[0021] Sensor system 165 is shown schematically in FIG. 2 and has a formfactor that may be easily integrated within product 105 without changingits packaging or shipping requirements. Sensor system 165 may include amicrocontroller interface 205, control circuitry 220, memory 215, apower source 225, one or more sensors 230, a sensor interface 260 toaccommodate additional sensors, a communications port 265, and a powerswitch 270.

[0022] Microcontroller interface 205 generally provides an interfacebetween the circuitry in sensor system 165 and microcontroller 110.Microcontroller interface may include analog to digital and digital toanalog converters, level shifters, multiplexers, demultiplexers, and anyother circuitry for providing a signal path between microcontroller 110and the circuitry of sensor system 165.

[0023] Control circuitry 220 may include logic circuitry for generallycontrolling the operation of sensor system 165, and may operate inconjunction with memory 215. For example, control circuitry 220 mayinclude a processor that operates programs found in memory 215. Memory215 may provide storage for measurements acquired by the one or moresensors 230. Memory 215 may be arranged as a 128 K×8, 1 Mbit flashmemory with a serial address and data bus. Memory 215 may also beconfigured as a non-volatile memory which retains its contents in theevent of a power loss. In one embodiment, the above mentioned programs170 that may be accessed by microcontroller 110 for controlling andinteracting with sensor system 165 may be stored in memory 215, inaddition or as an alternative to storing them in on-board memory 120.

[0024] Power source 225 may use lithium cell construction and may be forexample, a 2000 MaH lithium battery pack. In this embodiment, powersource 225 supplies power to the components of sensor system 165, and tomicrocontroller 110. In another embodiment power source 225 may be aconventional power supply or a battery power supply provided as part ofmicrocontroller 110.

[0025] The one or more sensors 230 may include sensors for detectingvarious types of conditions, for example environmental conditions,locations, or time periods. More particularly, sensors 230 may include,for example, a humidity sensor 235, a temperature sensor 240, anaccelerometer 245, a timer 250, and a global positioning system (GPS)sensor 225. Each of the one or more sensors 230 may include suitablesupport circuitry, for example, amplifiers, filters, and converters, andmay be capable of providing an analog output or a digital output asrequired. Each of the sensors 230 may be connected individually or via abus to other circuitry, and may also be capable of generating aninterrupt, alarm, or some other type of alert in the event that one ormore particular conditions exist, or that any number of thresholds havebeen exceeded or have not been met. One or more of the sensors 230 mayinclude a “sample and hold” capability where a particular measurementmay be latched or otherwise held until read from the particular sensor.Any number of the sensors 230 may also include identifying circuitry forallowing another device to determine the presence, location, type, andcapabilities of each sensor 230 having such circuitry.

[0026] Humidity sensor 235 may be a capacitive humidity sensor withappropriate support circuitry, an analog output humidity module, or adigital output humidity module. In one embodiment, humidity sensor iscapable of sensing a range of from about 0% to about 100% relativehumidity.

[0027] Temperature sensor 240 may be a thermistor, thermocouple, or aresistance temperature device (RTD) with suitable support circuitry.Temperature sensor 240 may be capable of measuring a temperature in therange of from about −55 to about +125 degrees C., and may provide ananalog or digital output.

[0028] Accelerometer 245 may be multi-axial, that is, it may be capableof measuring acceleration in two or three orthogonal directionssimultaneously. Accelerometer 245 may be capable of measuring a range ofacceleration from about 0 to 100 g's.

[0029] Timer 250 may be capable of measuring elapsed time or particulartime periods. Timer 250 may be a programmable device capable of startingor stopping upon receiving a trigger and of generating a signal upon theexpiration of a particular period. Timer 250 may be triggered by othersensors of sensor system 165. For example, timer 250 may be used tomeasure total time spent in the distribution channel, an amount of timespent at a particular humidity level, or an amount of time spent below aparticular temperature threshold.

[0030] GPS sensor 255 is generally capable of receiving signals from theGlobal Positioning System and providing information related to theglobal location of sensor system 165. GPS sensor 255 may include supportcircuitry for converting the received signals to coordinates and forconveying those coordinates to other circuitry of sensor system 165 andto microcontroller 110.

[0031] Sensor interface 260 provides a connection point for anyadditional sensors that may be desired. Sensor interface 260 may includeone or more connectors, clips, pads, or other devices for providingelectrical contacts for connecting sensors to sensor system 165. Inaddition, sensor interface 260 may include through holes, pins,standoffs or other mounting devices for physically supporting theadditional sensors.

[0032] Communications port 265 provides a communications interface to anexternal device such as a computer (not shown). Communications port 265may be an RS 232, 422, or universal serial bus (USB) serial port and mayinclude a connector 275 for connection to the external device.

[0033] Power switch 270 is coupled to communications port 265 and isoperable to apply power to communications port 265 when the externaldevice is plugged in or otherwise connected to connector 275.

[0034] Examples of the operation of the data acquisition system 100 willnow be described with reference to FIGS. 1 and 2. In one embodiment,when sensor system 165 is connected to microcontroller 110, power source225 supplies power to microcontroller 110. Microcontroller 110recognizes that sensor system 165 is connected and accesses programs 170from on-board memory 120 or from memory 215 to operate sensor system165. Microcontroller may operate exclusively to control sensor system165, or may control sensor system 165 while performing other operationsassociated with product 105.

[0035] Upon recognizing that sensor system 165 is connected, undercontrol of programs 170, microcontroller 110 may initialize itself andcause the components of sensor system 165 to initialize. Programs 170may then cause microcontroller to determine the presence type andcapabilities of sensors 230 and set thresholds and alert parameters asappropriate for measuring particular conditions to which product 105 maybe subjected. Individual ones of sensors 230 may also set up to generateinterrupts upon reaching or failing to reach certain thresholds orgenerally upon measuring certain conditions. RTC 130 may also beprogrammed to generate an interrupt for microcontroller 110 on aperiodic or other basis.

[0036] After completing the above mentioned initialization and setupprocedures, microcontroller 110 may then enter a “sleep” mode havinglimited functionality and power requirements. For example,microcontroller 110 may disable A/D 125, UART 135, and a portion ofon-board memory 120, and may operate microprocessor 115 in a reducedpower mode where it may only respond to certain interrupts, such asthose from RTC 130 and sensor system 165.

[0037] Upon receiving an interrupt from RTC 130 or sensor system 165,microprocessor 115 may enable all circuitry of microcontroller 110, andmicrocontroller 110 may operate to examine the interrupt and identify aservice routine to be performed. For example, an RTC generated interruptmay be serviced by reading the current humidity from humidity sensor235, the current temperature from temperature sensor 240, locationinformation from GPS sensor 255 and a time value from RTC 130. A dateand time stamp may then be generated from the time value and associatedwith the temperature, humidity, and location measurements and then themeasurements and associated time and date stamp may be stored in memory215.

[0038] As another example, accelerometer 245 may be programmed togenerate an interrupt upon exceeding a particular acceleration value,for example, 5 g's. Upon exceeding that threshold, an interrupt isgenerated, microcontroller 110 identifies the type of interrupt serviceroutine required and reads the acceleration value, location information,and time value from accelerometer 245, GPS sensor 255, and RTC 130,respectively. These values may then be stored in memory 215.

[0039] The contents of memory 215 may be retained until product 105reaches a particular location, for example, a final destination, or whenan end user takes possession. When desired, the contents of memory 215may be read and used to analyze the conditions to which product 105 hasbeen subjected.

[0040] In one embodiment, the contents of memory 215 may be obtained byplugging a suitable connector, connected to an external computer orother device, into connector 275 of communications port 265. Forexample, plugging into connector 275 may cause power switch to energizecommunications port 265 and connector 275, and may generate an interruptto microcontroller 110. Upon receiving the interrupt, microcontroller110 examines the interrupt, identifies the appropriate service routineand proceeds to send the measurements stored in memory 215 tocommunications port 265 and out through connector 275.

[0041] In another embodiment, the contents of memory 215 may be obtainedby a request or communication through network 145, for example fromenterprise 140. A user at one of the computers 155 may generate such arequest, or the request may be generated automatically by one of thecomputers 155, for example, upon a data entry that product 105 hasarrived at an end user destination. The request may be routed throughinternal network 160 to computer 150 and then through network 145 tomicrocontroller 110. Upon receiving the request, microcontroller 110causes the measurements stored in memory 215 to be transmitted back tothe requesting computer 155. Optionally, the request may specify analternate destination for the measurements and microcontroller 110 maycause the measurements to be sent to the alternate destination.

[0042] While the present invention has been discussed in the context ofrecording shipping conditions, it should be understood that the presentinvention may also be used to monitor conditions during any phase of thelife cycle of product 105. For example, system 100 could be used todetect improper storage or operating temperatures that may void awarranty for sensitive equipment. System 100 may also be used to senseconditions that may signify abuse of product 105, use beyond ratedspecifications, or to record anomalous conditions occurringintermittently in a normal user environment.

[0043] The present invention advantageously provides a data acquisitionsystem that is relatively inexpensive and that may be easily integratedinto an existing product. This facilitates collecting data from a largesample population, or may even be used for every instance of aparticular product. The invention also provides a data acquisitionsystem that does not require modification of existing packaging ormodification of the form factor of a product. As a further advantage,the invention provides for straightforward data retrieval through acommunications port or through a network.

[0044] It should be understood that the foregoing description is onlyillustrative of the invention. Various alternatives and modificationscan be devised by those skilled in the art without departing from theinvention. Accordingly, the present invention is intended to embrace allsuch alternatives, modifications and variances.

We claim:
 1. A data acquisition system comprising: a product forshipment to an end user; a sensor system removably connected to theproduct for recording environmental conditions to which the product isexposed; and a computing device, which upon being connected to theproduct, is operable to retrieve the recorded environmental conditions.2. The system of claim 1, wherein the product is operable to control theoperation of the sensor system.
 3. The system of claim 1, wherein theproduct further comprises a device for storing the recordedenvironmental conditions.
 4. The system of claim 1, wherein the sensorsystem is operable to record environmental conditions independent of theoperation of the product.
 5. The system of claim 1, wherein the sensorsystem further comprises a device for storing the recorded environmentalconditions.
 6. The system of claim 1, wherein the computing device, uponbeing connected to the sensor system, is operable to retrieve therecorded environmental conditions.
 7. The system of claim 6, wherein thesensor system further comprises a communication port for providing therecorded environmental conditions to the computing device.
 8. The systemof claim 1, wherein the sensor system further comprises one or more of ahumidity sensor, a temperature sensor, an acceleration sensor, and aposition sensor.
 9. The system of claim 1, wherein the computing devicefurther comprises a program operable to analyze the retrieved recordedenvironmental conditions.
 10. A product for shipment to an and usercomprising: a sensor system removably connected to the product forrecording environmental conditions to which the product is exposed; anda communication port for communicating with a computing device, whichupon being connected to the product, is operable to retrieve therecorded environmental conditions.
 11. The product of claim 10, furthercomprising a function to control the operation of the sensor system. 12.The product of claim 10, further comprising a device for storing therecorded environmental conditions.
 13. The product of claim 10, whereinthe sensor system is operable to record environmental conditionsindependent of the operation of the product.
 14. The product of claim10, wherein the sensor system further comprises a device for storing therecorded environmental conditions.
 15. The product of claim 10, whereinthe sensor system further comprises a communication port for providingthe recorded environmental conditions to the computing device.
 16. Theproduct of claim 10, wherein the sensor system further comprises one ormore of a humidity sensor, a temperature sensor, an acceleration sensor,and a position sensor.
 17. A sensor system for removable connection to aproduct for shipment to an end user, comprising: an interface to theproduct; and one or more sensors for recording environmental conditionsto which the product is subjected, wherein the sensor system is operableto provide the recorded environmental conditions to a computing device,upon the computing device being connected to the product.
 18. The sensorsystem of claim 17, further comprising a controller for operating thesensor system independently of the operation of the product.
 19. Thesensor system of claim 17, further comprising a device for storing therecorded environmental conditions.
 20. The sensor system of claim 17,further comprising one or more of a humidity sensor, a temperaturesensor, an acceleration sensor, and a position sensor.